Chromium catalyst compositions and ethylene polymerization processes therewith

Abstract: This invention provides a chromium catalyst system that comprises [a] a support that comprises silica, wherein said support has a surface area to pore volume relationship as follows 0.5 ≦ Pore volume ≦ f(SA) wherein said f(SA) is (1.14x10 -7 )(SA) 3 - (1.19x10 -4 )(SA) 2 + (3.19x10 -2 )(SA) + 0.20; and [b] a hexavalent chromium compound; wherein the surface concentration of said hexavalent chromium on said support is from 0.25 to 1 hexavalent chromium atoms per square nanometer. Another embodiment of this invention provides a process to homopolymerize ethylene, or copolymerize ethylene with a comonomer, said process comprises polymerizing ethylene with the above chromium catalyst composition.

Description: BACKGROUND OF THE INVENTION This invention is related to the field of chromium catalyst compositions. This invention is also related to the field of ethylene polymerization processes catalyzed with chromium catalyst compositions. The terms "ethylene polymer", "ethylene polymers" and "polyethylene" for the purposes of this application shall mean homopolymer(s) comprising ethylene and/or copolymer(s) comprising a major amount of ethylene (≥50 mole percent) and a minor amount of comonomer <50 mole percent). It has long been recognized that the processability of an ethylene polymer is significantly affected by the amount of long chain branching in its molecular structure. This is because long chain branches give an ethylene polymer (when compared to ethylene polymers not having long chain branches) having a high viscosity under low shear conditions and a low viscosity under high shear conditions. Having a low viscosity under high shear conditions can increase the rate at which the ethylene polymer can be processed, thereby making the process more efficient. Furthermore, long chain branching is known to reduce die swell during blowmolding operations and increase bubble stability during film blowing operations. Since long chain branching has such a large affect on the rheological properties, it would be advantageous to be able to control the amount of long chain branching in an ethylene polymer. GB-A-1 294 689 and US-A-4 053 565 relate to a supported catalyst and a support thereof, respectively, for producing relatively low molecular weight, high melt index polyolefins. The catalyst comprises a metal-containing catalytic material deposited on a support which comprises a specific silica xerogel having a defined surface area and pore volume. US-A-4 053 435 discloses a further chromium catalyst for producing ethylene polymers of low molecular weight and high melt index, which catalyst is supported on a specially-prepared silica-aerogel having both a large surface area and a large average pore volume. Ethylene polymers produced using chromium catalyst compositions have very low levels of long chain branching. However, even at these low levels, long chain branching has a significant affect on the rheological properties of an ethylene polymer. Therefore, it would be advantageous to be able to control the amount of long chain branching in an ethylene polymer that is produced by a chromium catalyst composition. SUMMARY OF THE INVENTION It is an object of this invention to provide a chromium catalyst composition. It is another object of this invention to provide a chromium catalyst composition that is useful for homopolymerizing ethylene, or copolymerizing ethylene with a comonomer, to produce a ethylene polymer that has an increased amount of long chain branching and a decreased amount of die swell. It is another object of this invention to provide a process to use this chromium catalyst composition to produce an ethylene polymer that has an increased amount of long chain branching and a decreased amount of die swell. In accordance with this invention a chromium catalyst composition is provided as defined in claim 1. In accordance with another embodiment of this invention a process to homopolymerize ethylene, or copolymerize ethylene with a comonomer, is provided, as defined in claim 14, said process comprises polymerizing ethylene with the above chromium catalyst composition. These and other objects, features, aspects, and advantages of the invention will become better understood with reference to the following figures, descriptions, and claims. BRIEF DESCRIPTION OF THE FIGURES The following is a brief description of the figures. FIGURE 1 is a graph of the tan delta vs. the weight average molecular weight for ethylene polymers produced from chromium/silica catalysts. FIGURE 2 is a graph of the shear response vs. the weight average molecular weight for ethylene polymers produced from chromium/silica catalysts. FIGURE 3 is a graph of the tan delta vs. the weight average molecular weight for ethylene polymers produced from chromium/silica catalysts. FIGURE 4 is a graph of the tan delta vs. the weight average molecular weight for ethylene polymers produced from chromium/silica-titania catalysts. FIGURE 5 is a graph of the shear response vs. the weight average molecular weight for ethylene polymers produced from chromium/silica-titania catalysts. FIGURE 6 is a graph of the tan delta vs. the activation temperature for ethylene polymers produced from catalyst 29. FIGURE 7 is a graph of the tan delta vs. the weight average molecular weight for ethylene polymers produced from catalyst 26. FIGURE 8 is a graph of the tan delta vs. the weight average molecular weight for ethylene polymers produced with catalysts that have varying amounts of sodium. FIGURE 9 is a graph of the shear response vs. the weight average molecular weight for ethylene polymers produced with catalysts that have varying amounts of sodium. FIGURE 10 is a graph of the tan delta vs. the weight average molecular weight for ethylene polymers produced with catalysts that have varying amounts of chromium. FIGURE 11 is a graph of the shear response vs. the weight average molecular weight for ethylene polymers produced with catalysts that have varying amounts of chromium. FIGURE 12 is a graph of the tan delta vs. the weight average molecular weight for ethylene polymers produced with catalyst 25. FIGURE 13 is a graph of the catalyst pore volume vs. the catalyst surface area. FIGURE 14 is a graph of the molecular weight distribution for ethylene polymers produced with catalysts that have various levels of chromium. FIGURE 15 is a graph of the molecular weight distribution for ethylene polymers produced with catalysts that have various levels of chromium. FIGURE 16 is a graph of the tan delta vs. the high load melt index for ethylene polymers produced with catalyst A. FIGURE 17 is a graph of the eta ratio vs. the high load melt index for ethylene polymers produced with catalyst A. FIGURE 18 is a graph of the eta ratio vs. the surface concentration of hexavalent chromium for ethylene polymers produced with catalyst A. FIGURE 19 is a graph of the eta ratio vs. the surface concentration of hexavalent chromium for ethylene polymers produced with catalyst A. DETAILED DESCRIPTION OF THE INVENTION In general, the chromium catalyst compositions as defined in claim 1, used in this invention comprise a chromium component and a support component. The support component is not meant to be construed as an inert component of the chromium catalyst composition. The support is generally composed of 80 to 100 wt.% silica. The remainder, if any, being selected from the group consisting of refractory metal oxides, such as alumina, boria, magnesia, thoria, zirconia, titania, and mixtures of two or more of these refractory metal oxides. It is preferred however, that the remainder, if any, consists essentially of titania. The support can be prepared in accordance with any method known in the art. Suitable methods are disclosed in U.S. patent 3,900,457; 4,081,407; 4,392,990; 4,405,501; 4,735,931; and 4,981,831; the entire disclosures of which are hereby incorporated by reference. In a preferred embodiment the support is calcined at a temperature from 750 to 1000°C. It is important that the support have a surface area to pore volume relationship as follows: 0.5 ≤ pore volume < f(SA) wherein the f(SA) is (1.14x10 -7 )(SA) 3 - (1.19x10 -4 )(SA) 2 + (3.19x10 -2 )(SA) + 0.20. It is preferred if the surface area of the support is from 50 m 2 /g to 500 m 2 /g. It is more preferred if the surface area is from 100 m 2 /g to 300 m 2 /g. If the surface area is substantially greater than 500 m 2 /g then the polymer produced by this catalyst will not possess the desired amount of long chain branching. If the surface area is substantially less than 50 m 2 /g then the support cannot carry enough hexavalent chromium to form a high activity catalyst composition. It is also preferred if the pore volume is from 0.5 to 2.5 cm 3 /g. However, it is more preferred if the pore volume is from 1 to 2 cm 3 /g. If the pore volume is substantially greater than 2.5 cm 3 /g then the polymer produced by this catalyst composition will not possess the desired amount of long chain branching. If the pore volume is substantially less than 0.5 cm 3 /g then the catalyst composition will have low activity. One method to affect the surface area of the support is by contacting the support with aqueous ammonia. The aqueous ammonia should have a pH greater than 7. However, it is preferred if the aqueous ammonia has a pH from 8 to 11. The support can be contacted with the aqueous ammonia for a time period in the range of 1 minute to 100 hours. However, depending on the desired surface area longer contact times tend to produce smaller surface areas. The chromium component of the chromium catalyst composition comprises a chromium compound. Suitable chromium compounds are chromium nitrate, chromium acetate, and chromium trioxide. The amount of the hexavalent chromium combined with the support is from 0.5 wt.% to 5 wt.%, preferably it is from 1 wt.% to 4 wt.%, and most preferably it is 1 wt.% to 3 wt.% based on the combined weight of the chromium compound and the support. If the amount of chromium is substantially greater than 5 wt.% then the activity of the catalyst composition is undesirably low and the resulting polymer has an unacceptable color. If the amount of chromium is substantially less than 0.5 wt.% then the activity of the catalyst composition is undesirably low and the resulting polymer does not have the desired amount of long chain branching. The chromium compound can be combined with the support in any manner known in the art. Examples of combining the chromium compound with the support are disclosed in the above-cited and incorporated patents. It is important that the valence state of the chromium in the chromium compound be six. In other words, hexavalent chromium is the preferred catalytic species. The surface concentration of the hexavalent chromium on the support must be from 0.4 to 1 hexavalent chromium atom per square nanometer. A Group I metal can be contacted with the chromium catalyst composition to further increase the amount of long chain branching in a resulting polymer. The amount of the Group I metal to contact with chromium catalyst composition is from 1 to 5000 parts per million by weight based on the weight of the chromium catalyst composition. However, it is preferred, if the amount of the Group I metal is from 100 to 3000 parts per million. Sodium and potassium are the preferred Group I metals to use in this regard. The chromium catalyst composition can be activated in a variety of ways. In general, activation occurs when the chromium compound is contacted with an oxygen-containing ambient. This contacting should take place at a temperature from 500°C to 1000°C. However, the proper temperature range depends on the composition that is to be activated and how that composition will be used. For example, if the chromium catalyst composition is going to be used without a cocatalyst then the chromium catalyst composition should be activated at a temperature from 750°C to 1000°C. However, it is preferred if the chromium catalyst composition in this case is activated at a temperature from 800°C to 1000°C. However, it is even more preferred if the chromium catalyst composition is activated at a temperature from 800°C to 925°C. If the chromium catalyst composition is going to be used with a cocatalyst, a lower activation temperature can be used. In this case, the chromium catalyst composition can be activated at a temperature from 500°C to 700°C. However, it is preferred if the chromium catalyst composition, in this case, is activated at a temperature from 600°C to 700°C. After this activation, the chromium catalyst composition can be used to homopolymerize ethylene, or copolymerize ethylene with a comonomer. A preferred polymerization technique is a slurry polymerization process also known as the particle form process. Such polymerization techniques are well known in the art and are disclosed, for instance, in Norwood, U.S. patent 3,248,179; the entire disclosure of which is hereby incorporated by reference. Two preferred polymerization methods for the slurry process are those employing a loop reactor of the type disclosed in Norwood and those utilized in a plurality of stirred reactors either in series, parallel, or combinations thereof, wherein the reaction conditions are different in the different reactors. It is possible to copolymerize ethylene with a comonomer during the polymerization. The comonomers that can be copolymerized with ethylene should have from three to 20 carbon atoms in their molecular chain. They can be either linear or branched, but linear comonomers are preferred. Suitable examples of comonomers are propylene, 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, 3-ethyl-1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and mixtures of two or more said comonomers. In the polymerization process of this invention a trialkylaluminum cocatalyst can be present during the polymerization. In general, the alkyl groups of the trialkylaluminum cocatalyst should have from 1 to 10 carbon atoms and preferably 2 to 4 carbon atoms. Examples, include but are not limited to, triethylaluminum, tripropylaluminum, and trimethylaluminum. However, most preferred is triethylaluminum. The amount of trialkylaluminum cocatalyst used in the polymerization, in parts per million by weight, based on the weight of the diluent in the reactor, is from 0.01 parts per million to 20 parts per million, preferably it is from 0.05 parts per million to 10 parts per million and most preferably it is from 0.5 to 5 parts per million. If a trialkylaluminum cocatalyst is not present during the polymerization, a trialkylboron compound should be present. In general, the alkyl groups of the trialkylboron cocatalyst should have from 1 to 10 carbon atoms and preferably 2 to 4 carbon atoms. Examples include, but are not limited to, triethylboron, tripropylboron, and trimethylboron. However, most preferred is triethylboron. The amount of trialkylboron cocatalyst used in a polymerization, stated in parts per million by weight, based on the weight of the diluent in the reactor, is from 0.01 parts per million to 20 parts per million. Preferably it is from 0.05 parts per million to 10 parts per million, and most preferably it is from 0.5 parts per million to 5 parts per million. It is important to this invention that the polymerization temperature should be from 80°C to 110°C. However, it is preferred if the reaction polymerization temperature is from 95°C to 105°C. If the temperature is substantially greater than 100°C the reactor can foul and the resulting polymer will not possess the desired amount of long chain branching. If the temperature is substantially less than 80°C the catalyst activity is too low and the resulting polymer has a melt index which is undesirably low. EXAMPLES These examples are provided to further assist a person skilled in the art with understanding this invention. The particular reactants, conditions and the like, are intended to be generally illustrative of this invention and are not meant to be construed as unduly limiting the reasonable scope of the invention. EXAMPLE ONE Catalysts The catalysts used in the initial portion of this example are listed in Table 1. All were prepared with 1% chromium and activated at 750°C, in order to determine the relationship of catalyst pore structure to long chain branching. These catalysts consist of commercial polyolefin catalysts, chromatographic silicas, colloidal silicas, and others. Some of the catalysts have low activity, but this selection provides a wide range of pore structures, allowing the pore volume, surface area, and pore size to be studied. For analysis purposes, these catalysts were divided into three groups, according to the composition of the support. Group 1 (Catalysts 1-19, and 29): This group consists of catalysts that have silica as their support. It could be broken down further by analyzing catalysts 4-9 separately from the other silica-based catalysts because of their different nature. Catalysts 4-9 are colloidal sized silica particles, and they were prepared as catalysts by two methods in order to vary the degree of particle aggregation. In preparation method A, chromium was deposited on the silica from a methanolic solution. During methanol removal, considerable particle aggregation occurred due to the surface tension of the evaporating methanol. This is shown by the high pore volume (Table 2) since individual nonporous particles should have no pore volume. In preparation method D, catalysts 5, 7, and 9 were reacted with chromyl chloride vapor. Some particle aggregation still occurred because of the high activation temperature, but it was reduced as shown by the lower pore volume (Table 2). Group II (Catalyst 20): Is a catalyst in which the pores have been filled with aluminum phosphate. We have no other catalysts of this type, so it was compared with other catalysts which gave similar molecular weights. Group III (Catalysts 21-26): Silica/titania was used as the catalyst support with titanium levels of 2-5%. The pore structure properties were determined from the nitrogen adsorption and desorption isotherms for all catalysts used in this example and the results are listed in Table 2. The average pore radius was calculated from the pore volume and surface area according to equation 1. (1) Average Pore Radius (in 10 -1 nm ("Angstroms")) = (2 X Pore Volume in (cm 3 /g)/Surface Area in (m 2 /g)) X 10 4 Catalysts Giving Long Chain Branching: All polymerizations were carried out under the same conditions using 2 ppm of TEA as a poison scavenger due to problems with the isobutane supply. The activities of the various catalysts are shown in Table 3. The resulting polymers were analyzed for long chain branching by comparing the melt rheology (Table 4) and size exclusion chromatography (SEC) data (Table 5) to determine if the resin has higher elasticity than can be justified by the molecular weight. For samples where the viscosity was too high to obtain the SEC, M w was estimated from M v . This was done by assuming that M w /M v = 1.4 since all polymers for which the SEC was obtained had M w /M v = 1.31-1.54. Our conclusions on which catalysts gave higher levels of long chain branching are summarized in Table 6. The basis for these conclusions are given in the following paragraphs. a. Silica Catalysts In order to simplify the analysis of silica catalysts for long chain branch formation, the polymers produced from catalysts 4-9 were initially omitted. The rheology of the polyethylene from the remaining catalysts shows two distinct families. Family 1 (consisting of polymers produced from catalysts 29C, 7, 3, 10, and 19) has a lower tan delta (Figure 1) and higher shear response (Figure 2) showing that these polymers have greater elasticity. Their rheological properties also have a greater dependence on molecular weight than family 2 as shown by the sharper slopes in Figures 1 and 2. With the exception of the polymer produced from catalyst 19, family 1 polymers have narrow MWD's (Table 5), which is normally associated with low shear response. Therefore, the greater shear response and elasticity of this group must be due to long chain branching. The M w of the polymer produced from catalyst 18 was estimated from the M v to be 431,000. This places it between family 1 and family 2 in Figures 1 and 2. This could be due to the presence of some long chain branching or to a very broad MWD. Without the SEC it is difficult to say which. When the polymers produced from catalysts 4-9 are added, the separation into groups is not as clear (Figure 3). The polymer produced from catalyst 8 lies directly in line with family 1, suggesting that it has long chain branching. The polymers from catalysts 4 and 6 fall between the two families, but this is probably due to their broad MWDs. The polymers produced from catalysts 5, 7, and 9 are in family 2 with no long chain branching. b. Silica-titania Catalysts The rheology results for the titania containing catalysts are shown in Figures 4 and 5. There are two noticeable trends here. (1) The polymers produced from catalysts 24 and 25 have higher elasticity than the polymer produced from catalysts 21 and 22, even though their M w is about the same. But they have very broad MWD's which account for this increased elasticity. (2) Even though the polymer produced from catalyst 26 has a much lower M w than the polymer produced from catalyst 23, its elasticity is approximately the same. The HI difference is not enough to account for this, so the resin produced from catalyst 26 must have long chain branching which is contributing to its elasticity. c. Catalyst 20 We have no other catalysts with the same support composition as catalyst 20. Therefore, the polymer produced from catalyst 20 was compared to those from 14, 17, and 23 since they have similar molecular weights. The HI of the polymer (Table 5) is comparable to that of the polymers produced from catalysts 14 and 23, and much lower than that of the polymer produced from catalyst 17. But still the polymer produced from catalyst 20 possesses a much lower tan delta and higher shear response. This high elasticity must be due to long chain branching. Other Parameters Affecting Long Chain Branching: a. Effect of Activation Temperature Catalyst 29 was activated at different temperatures to determine if catalyst activation temperature has any effect on long chain branching. As the activation temperature was increased, the catalyst pore volume and surface area decreased while the average pore radius remained about the same (Table 7). This change in pore structure was minor below 750°C, but it became rapid at higher temperatures. The intrinsic viscosities in Table 8 show that the molecular weight of polyethylene decreases as the catalyst activation temperature is increased. Thus, the elasticity of these samples should also decrease as the activation temperature is increased. An increase in tan delta in Figure 6 shows that the elasticity is decreasing as expected when the temperature is increased from 450°C to 750°C. However, above 750°C activation, the elasticity begins to increase. This could be due to either a broadening of the molecular weight distribution or to long chain branching. Table 8 shows that the molecular weight distribution is narrow at high activation temperatures (HI=7.1 for 1000°C activation). Therefore, we must conclude that the increase in elasticity on increasing the activation temperature is due to increasing amounts of long chain branching. The trend in Figure 6 shows that long chain branching increases with activation temperature above 750°C, but it is likely that this effect also applies at lower temperatures. This plot results from two variables, decreasing molecular weight and increasing long chain branching. There is a sharp decrease in molecular weight on increasing the activation temperature from 450°C to 750°C. This molecular weight change hides any increase in elasticity which could be due to long chain branching. Above 750°C, the molecular weight decrease begins to level off allowing the long chain branching effect to become apparent. This becomes more apparent in Figure 7 which shows tan delta vs M w for a series of resins produced from catalyst 26 (activated at different temperatures). It shows that tan delta increases (or long chain branching decreases) with decreasing activation temperature down to a temperature of at least 593°C. b. Sodium Effect In order to look at the effect of Na, the catalysts in Table 9 were prepared. Catalysts 32 and 35 were prepared by hydrolysis of tetraethyl orthosilicate, so they have very low Na contents. Each was run with different levels of added sodium. The effect of Na and Ti on the catalyst pore size distribution is shown in Table 9. As expected, when the Na level increases, pore volume and surface area decrease in much the same way as when the activation temperature is increased. This is due to a lowering of the catalyst sintering temperature. The rheology data for these polymers is given in Table 10. Figures 8 and 9 show plots with this data divided into two series. Catalysts 32-34 do not appear to give long chain branches even though 33 and 34 have high Na contents. In the series 35-37, catalyst 35 does not appear to give long chain branching, but when the Na content is increased in 36 and 37, tan delta decreases and shear response increases even though there is;a large decrease in M w . This suggests that 36 and 37 contain long chain branching. This shows that addition of sodium affects long chain branching in some cases, but not in all cases. In order to look further at the effect of sodium on long chain branching, the sodium content of some of the catalysts in Table 1 were determined by plasma digestate analysis. The results are given in Table 11. They show that the sodium content does not have a direct effect on long chain branching, because there is a wide range of sodium contents in the catalysts which gave long chain branching (<53 to 2220 ppm Na) as well as in those that did not give long chain branching (<52 to 452 ppm Na). c. Effect of Chromium Content Polyethylene samples were obtained which had been produced with catalyst 38. Catalyst 38 contained various levels of chromium. The polymer properties are shown in Table 12. Figures 10 and 11 show that as the chromium content is increased up to 0.4%, the elasticity of the resin increases rapidly even though there are only slight increases in M w and HI. Above 0.4% Cr, M w increases much more rapidly but the elasticity appears to level off. This shows that long chain branching increases with chromium content up to 0.4% Cr, but then it reaches a saturation point where further increases in Cr have less of an effect. d. Effect of Reaction Temperature The catalyst 25A was run at various reaction temperatures to see if this affected the long chain branching (Table 13). As reaction temperature was increased, M w decreased and the molecular weight distribution narrowed. Figure 12 shows that the polymer produced at 108°C has much higher tan delta and crossover modulus than expected. This suggests that fewer long chain branches are formed at high reaction temperatures. The similarity of the calculated and measured inherent viscosities (Table 13) also suggest that the resin produced at 108°C is behaving more like linear chains. Initial Catalyst Preparations The catalysts used in the initial portion of this example were prepared by one of the following methods as designated in Table 1. Method A The support was wetted with a solution of methanol containing enough chromium nitrate to give 1% Cr based on the weight of support. The methanol was removed by heating at 100°C under vacuum. Method B Catalyst 14 was prepared as in Method A, except an aqueous solution of chromium nitrate was used. This gave a catalyst with lower pore volume than catalyst 13 (the base catalyst for catalyst 14) due to contraction of the pores by the surface tension of the water as it evaporated. Method C Catalyst 23 was prepared by wetting catalyst 22 with deionized water and drying at 100°C under vacuum to reduce the pore volume. Method D Catalysts 5, 7, and 9 were prepared by this method in order to prevent aggregation of the colloidal silica particles during the methanol drying step in Method A. The silica (5 g) was placed in an activator tube with a stream of dry nitrogen flowing through it. Then 0.08 ml of chromyl chloride (1.0% Cr based on the weight of silica) was injected into the nitrogen stream below the silica. The chromyl chloride slowly evaporated and was carried by the nitrogen into the silica where it reacted. The fluidizing gas was changed to air and the temperature was raised to 750°C for 3 hr to give the activated catalyst. Colloidal silicas are very fluffy and do not fluidize well. This allowed a portion of the chromyl chloride to pass through the silica without reacting. Plasma digestate analysis showed that catalysts 5, 7, and 9 contained only 0.88, 0.73, and 0.50% Cr, respectively. Method E Commercial catalysts which contained Cr were simply activated as described below. Catalyst 32 - Silbond 40 (200 ml), 200 ml of 1-propanol, and 10 ml of concentrated ammonium hydroxide were stirred for 5 min at room temperature. Titanium isopropoxide (10 ml) was added and stirred for 5 min to give 1.5% Ti. Deionized water (40 ml) was then added and gelation occurred within 30 sec giving a clear gel, which was aged 84 hr at room temperature and 2 hr at reflux. It was then dried at 80°C under vacuum for 24 hr to give the titanated silica. This silica was wetted with a solution of chromium nitrate in methanol, and dried at 100°C under vacuum to give 1% Cr. Catalyst 35 - Prepared as catalyst 32, except no titanium isopropoxide was added. Addition of Sodium - Prepared as catalysts 32 or 35, except sodium nitrate was added to the chromium nitrate/methanol solution to give the desired amount of sodium in the final catalyst. Catalyst 33 = 32 + 1110 ppm Na Catalyst 34 = 32 + 1850 ppm Na Catalyst 36 = 35 + 1110 ppm Na Catalyst 37 = 35 + 1850 ppm Na Catalyst Activation - While the catalyst was fluidized by a stream of dry air, the temperature was raised at a rate of 400°C/hr to the desired temperature, where it was held for 3 hr. After cooling to room temperature, the catalyst was flushed with nitrogen giving the activated catalyst. Polymerizations - All polymerizations were carried out in a 2.6 l stainless steel reactor. After flushing the reactor with nitrogen and isobutane, 0.05 to 0.10 g of catalyst was charged. This was followed by addition of 600 ml of isobutane, 0.5 ml of 0.5 wt.% TEA in heptane, and an additional 600 ml of isobutane. The reactor was then heated to temperature and the pressure was brought up to the desired level by addition of ethylene. The pressure was maintained at this level throughout the reaction by addition of ethylene at the same rate it was consumed by reaction. Polymerization time was normally 45-60 minutes, depending on the catalyst activity. Rheology - Measurements were made at 190°C on fluff samples which were untreated and solvent treated (dissolved in 1,2,4-trimethylbenzene at 145°C and dried under vacuum at 125°C. Catalyst Properties Which Give Long Chain Branching The results given above make it apparent that pore size is not the determining factor in long chain branch formation. The catalysts giving long chain branches have average pore radii (APR) over a wide range. Analysis of the pore size distributions showed that there is also no incremental pore size which is unique to the catalysts giving long chain branches. Instead, the production of long chain branching appears to be a function of both pore volume and surface area as shown in Figure 13. The catalysts giving long chain branching are isolated in the low surface area and low pore volume portion of the plot. The only exceptions to this trend are catalysts 5, 7, and 9 reacted with chromyl chloride which do not give long chain branching even though they have very low pore volume and surface area. But these catalysts are very different from the other catalysts in this study because they are colloidal sized particles which were prepared under conditions to minimize aggregation of the particles. The pore size distribution shows that some aggregation occurred, but we do not know how tightly these aggregates are bound or how much of the surface area is on the outer surface rather than inside the aggregates. If the aggregates are loosely bound, they may readily break apart once polymerization begins causing them to behave more like high pore volume catalysts. Long chain branching can also be increased by sintering the catalyst to reduce pore volume and surface area. This can be done by adding an alkali metal to reduce the catalyst sintering temperature or by using a higher activation temperature. Conclusions This study gives us a better understanding of what chromium oxide catalyst properties control long chain branch formation. The pore structure has a significant effect, with low pore volume and low surface area favoring long chain branch formation. Other factors which affect long chain branching are activation temperature, activation time, chromium content, and reaction temperature. CATALYSTS Run No. Catalyst No. Support Preparation Method Activation Temp (°C) 1 1 Si A 750 2 2 Si E 750 3 3 Si E 750 4 4 Si A 750 5 5 Si D 750 6 6 Si A 750 7 7 Si D 750 8 8 Si A 750 9 9 Si D 750 10 10 Si A 750 11 11 Si A 750 12 12 Si A 750 13 13 Si A 750 14 14 Si B 750 15 15 Si A 750 16 16 Si A 750 17 17 Si A 750 18 18 Si A 750 19 19 Si A 750 20 20 Si/AlPO 4 E 750 21 21 Si/Ti A 750 22 22 Si/Ti E 750 23 23 Si/Ti C 750 24 24 Si/Ti E 750 25 25 Si/Ti E 750 26 26 Si/Ti E 750 CATALYST PROPERTIES Run No. Catalyst No. Surface Area(SA) (m 2 /g) Pore Volume(PV) (cm 3 /g) Pore Radius(APR) (10 -1 nm A)) 1 1 253 1.51 119.4 2 2 328 1.53 93.3 3 3 278 1.09 78.4 4 4 237 2.86 241.1 5 5 218 1.15 105.5 6 6 96 2.18 454.2 7 7 75 0.285 76.0 8 8 144 2.21 306.9 9 9 132 0.555 84.1 10 10 428 0.749 35.0 11 11 109 0.229 42.0 12 12 564 0.993 35.2 13 13 302 2.84 188.1 14 14 312 2.07 132.7 15 15 356 1.19 66.9 16 16 356 2.22 124.7 17 17 346 1.41 81.5 18 18 101 0.799 158.2 19 19 82 1.66 404.9 20 20 220 1.27 115.4 21 21 403 2.26 112.2 22 22 443 2.07 93.5 23 23 490 1.13 46.1 24 24 469 1.7 72.5 25 25 331 1.92 116.0 26 26 280 1.15 82.1 ACTIVITY OF CATALYSTS (Activ Temp = 750°C, Reaction Temp = 100°C, 2.0 ppm TEA) Run No. Catalyst No. Productivity (g/g) Time (min) Activity (g/g-hr) 1 1 2185 45 2910 2 2 2382 30 4764 3 3 2030 50 2440 4 4 2110 60 2110 5 5 873 60 873 6 6 371 60 371 7 7 745 60 745 8 8 762 60 762 9 9 840 70 720 10 10 906 60 906 11 11 0 70 0 12 12 2239 45 2986 13 13 3900 60 3900 14 14 2450 45 3266 15 15 1320 60 1320 16 16 1598 60 1598 17 17 2892 40 4338 18 18 193 70 166 19 19 2073 60 2073 20 20 2399 45 3198 21 21 3052 45 4070 22 22 4044 35 6933 23 23 2277 45 3035 24 24 2514 30 5028 25 25 7402 52 8541 26 26 2620 45 3493 Results of LCB Analysis Catalysts Giving LCB: 1 10 29 19 2 20 3 20 8 Catalysts Giving No (or low) LCB: 4 15 5 16 6 17 7 21 9 22 12 23 13 24 14 25 Inconclusive Results: 18 Inactive Catalyst: 11 Properties of a Catalyst with Varied Activation Temperatures Run No. Activation Temp (°C) Catalyst No. Surface Area (m 2 /g) Pore Volume (cm 3 /g) Ave. Pore Radius (10 -1 nm (A)) Activity (g/g-hr) 27 450 29A 255 1.68 131.8 2350 28 600 29B 259 1.56 120.5 4017 29 750 29C 245 1.57 128.2 3966 30 900 29D 170 1.20 141.2 3281 31 1000 29E 106 0.598 112.6 801 Sodium Content of Catalysts No. Catalyst ppm Na LCB Catalysts 29 952 1 422 2 667 3 589 8 <53 10 329 19 2220 20 193 26 912 Non-LCB Catalysts 4 <60 6 <54 12 152 13 202 15 <52 16 59 17 426 21 136 22 414 24 452 25 353 EXAMPLE TWO Chromium Concentration A series of catalysts was made, catalyst A, catalyst B, catalyst C, catalyst D, and catalyst E with Cr levels varied from 0.2 to 3.0 wt%. Catalyst A was activated at 593 and 816°C (1100 and 1500°F). All other catalysts were activate at 593°C (1100°F). As shown in Table 14, some sintering of the high pore volume catalysts occurred at high Cr levels. It is unclear whether the sintering is actually caused by the Cr or by an impurity in the Cr solution. The sintering is most evident in catalyst A where the surface area dropped from 430 m 2 /g at 0.2% Cr to 303 m 2 /g at 3.0% Cr. Some sintering also occurred in 593°C (1100°F) catalyst A and catalyst C. However, with the catalyst C and catalyst D, no sintering appears to have occurred at high Cr levels. This is most likely due to the lower pore volume of catalysts C and D making them more difficult to sinter. Table 15 shows the % conversion of Cr +3 to Cr +6 with each catalyst. The % conversion is dependent on the surface area of the catalyst, with the higher surface area catalysts supporting more Cr +6 . On all catalysts except catalyst C, approximately 0.75 Cr +6 /nm 2 can be supported at 593°C (1100°F) activation. With catalyst C, the Cr +6 saturation level is approximately 0.70 Cr +6 /nm 2 . When the activation temperature is increased to 816°C (1500°F), the saturation level on catalyst A decreases from 0.75 to 0.6-0.65 Cr +6 /nm 2 . Each of these catalysts was used to produce ethylene homopolymer in the bench-scale reactors. The reactor conditions and polymer properties are shown in Tables 16-20. Figures 14 and 15 show the changes in molecular weight distribution as the Cr concentration is changed on 816°C (1500°F) A. The molecular weight distribution shifts to lower molecular weight as the Cr increases from 0.2 to 0.6 wt%. Above 0.6 wt%, the Cr concentration has no effect on the molecular weight distribution. It appears that using more than 0.2-0.3 Cr +6 /nm 2 has no effect on molecular weight distribution. However, as shown in Figures 16 and 17, the rheology of the polyethylene does not show this saturation effect. Tan delta decreases and eta 0.1 /eta 100 increases as Cr increases from 0.2 to 3.0 wt% Cr. With all catalysts in this study, the rheological properties continue to change as long as more Cr +6 can be supported on the catalyst. Since the molecular weight distribution does not change at >0.2-3.0 Cr +6 /nm 2 , the rheological changes at high Cr levels must be caused by increased levels of long chain branching. When TEA was added to the reactor, it increased the activity of catalysts activated at low temperature, but had no effect on the activity of catalyst A activated at 816°C (1500°F). This is not surprising since at low activation temperature, the catalyst surface is not dehydroxylated well. This leaves more inactive sites which can be activated by the TEA. But at high activation temperatures, the surface is dehydrated more and the catalyst activity is much higher, suggesting that a higher percentage of the Cr sites are active. Since the number of active sites may be close to saturation without TEA, the TEA has little effect on activity. In view of the above results, TEA increases the shear response with catalysts activated at low temperatures (Figure 18), but has no effect on shear response at high activation temperatures (Figure 19). TEA appears to increase shear response only when it also increases activity. With every catalyst in this example, TEB gave a dramatic increase in shear response (Figures 18 and 19). But unlike TEA, it does not increase the catalyst activity. So the increase in shear response is probably not caused by a higher density of active sites. Instead, it is due to a change in the properties of the active Cr sites. These catalysts are all commercially available. Catalyst E support - 500 g of Catalyst E was heated in the muffle furnace at 550°C for 5 hr to convert the Cr +3 to Cr +6 . It was then washed with deionized water at 80°C until the color of the filtrate indicated that most of the Cr had been removed. It was washed three times in 4 l of 1-propanol at 80°C and dried overnight in the vacuum oven at 100°C. A 5-10 g portion of the dried catalyst E was activated at 593°C in air for 3 hr. Titration of this activated catalyst showed that the washed catalyst E contained only 0.077 wt% Cr +6 . This residual amount of Cr was taken into consideration when the various Cr levels were added to the catalyst so that the total Cr levels reported are the sum of the residual Cr and the added Cr. Catalyst B support - The catalyst B support was made by the same method described above. The amount of residual Cr found in it was 0.008 wt%. Catalyst D - Catalyst C was dried at 150°C for 3 hr while being fluidized with nitrogen. It was then slurried in dry hexane under a nitrogen atmosphere and 15.5 ml of titanium(IV) isopropoxide was added to give 2% Ti on the catalyst C. This was reacted for 2 hr at room temperature with occasional shaking of the flask. The catalyst D was dried at 100°C under a nitrogen atmosphere. Addition of Cr - The desired amount of chromium(III) nitrate nonahydrate was dissolved in enough methanol to completely fill the pores of the catalyst. The catalyst and solution were mixed well by shaking, then the catalyst was dried overnight in the vacuum oven at 100°C. Cr +6 Titrations - The catalyst (0.5-1.0 g) was placed in approximately 25 ml of water, 25 ml of 18 N sulfuric acid, and 4 drops of a 0.025 M solution of 1,10-phenanthroline iron(II) sulfate in water. This was titrated to the orange-red endpoint with a standardized ferrous ammonium sulfate solution. Pore volume and Surface Area - measured by nitrogen adsorption. Ethylene Polymerizations - All polymerizations were done in a 2.6 l autoclave. After flushing the reactor with nitrogen and isobutane, 0.05-0.10 g of catalyst was added, followed by 1.2 l of isobutane. The reactor was heated to the reaction temperature and pressured to 3.8 MPa gauge (550 psig) with ethylene. Ethylene was fed to the reactor on demand to maintain a constant pressure. Reactions were run to a productivity of approximately 3000 g/g except in a few cases where the catalyst activity was low. When desired, a solution of 0.5 wt% TEA or 1.0 wt% TEB in heptane was added from a charge vessel after 600 ml of isobutane had been added. Rheology Measurements - The polyethylene samples were compression molded into plaques at 180°C. Rheological measurements were then made on disk shaped samples which were punched from the plaques. Rheological data was obtained from a Rheometrics Dynamic Spectrometer (Model RMS-7700) at 190°C under a nitrogen atmosphere. In these examples the crossover modulus --G(x)-- is the modulus at the point where the storage modulus --G'-- is equal to the loss modulus --G"--. Effect of Cr Level on Pore Volume and Surface Area All catalysts were activated in air for 3 hr at the temperature shown Catalyst Wt% Total Cr Pore Volume (cm 3 /g) Surface Area m 2 /g A 0.2 2.49 456 593°C (1100°F) 0.4 2.49 452 0.6 2.43 435 0.8 2.43 441 1.0 2.43 440 2.0 2.23 403 C 0.2 1.56 270 593°C (1100°F) 0.6 1.58 277 1.0 1.64 290 2.0 1.70 287 3.0 1.53 265 E 0.2 2.12 559 593°C (1100°F) 0.6 1.93 501 1.0 2.08 540 2.0 1.99 533 3.0 1.85 514 D 0.2 1.56 270 593°C (1100°F) 0.6 1.58 277 1.0 1.64 290 2.0 1.70 287 3.0 1.53 265 A 0.2 2.35 430 816 °C (1500°F) * 0.4 2.34 429 0.6 2.31 423 0.8 2.46 455 1.0 2.25 411 2.0 2.14 392 3.0 1.52 303 Amount of Cr +6 Supported on Various Catalysts Catalyst Wt% Total Cr Wt% Cr +6 % Conversion Cr +6 nm 2 A 0.2 0.184 92 0.047 593°C (1100°F) 0.4 0.368 92 0.094 0.6 0.565 94 0.150 0.8 0.721 90 0.190 1.0 0.923 92 0.243 2.0 1.74 87 0.500 3.0 2.52 84 ― B 0.2 0.166 83 0.057 593°C (1100°F) 0.6 0.513 86 0.175 1.0 0.847 85 0.289 2.0 1.68 84 0.574 3.0 2.17 72 0.741 C 0.2 0.173 87 0.074 593°C (1100°F) 0.4 0.357 89 0.158 0.6 0.501 84 0.209 1.0 0.800 80 0.319 2.0 1.43 72 0.577 3.0 1.57 52 0.686 E 0.2 0.148 74 0.031 593°C (1100°F) 0.6 0.448 75 0.104 1.0 0.806 81 0.173 2.0 1.78 89 0.387 3.0 2.53 84 0.571 D 0.2 0.176 88 0.076 593°C (1100°F) 0.6 0.515 86 0.226 1.0 0.824 82 0.364 2.0 1.51 76 0.705 3.0 1.71 57 0.764 A 0.2 0.214 100 0.058 816°C (1500°F) 0.4 0.416 100 0.112 0.6 0.534 89 0.146 0.8 0.685 86 0.174 1.0 0.907 91 0.256 2.0 1.48 74 0.438 3.0 1.61 54 0.616

Claims: A chromium catalyst composition that is useful for homopolymerizing ethylene, or copolymerizing ethylene with a comonomer, to produce an ethylene polymer that has an increased amount of long chain branching and a decreased amount of die swell, said chromium catalyst composition comprises: (a) a support that comprises silica, wherein said support has a surface area (SA) to pore volume relationship as follows 0.5 ≤ Pore volume ≤ f(SA) wherein said f(SA) is (1.14x10 -7 )(SA) 3 - (1.19x10 -4 )(SA) 2 + (3.19x10 -2 )(SA) + 0.20; wherein the pore volume is given in (cm 3 /g) and the surface area is given in (m 2 /g); and (b) a hexavalent chromium compound; wherein the surface concentration of said hexavalent chromium on said support is from 0.4 to 1 hexavalent chromium atoms per square nanometer, said support has a surface area from 50 to 500 m 2 /g, and the amount of said hexavalent chromium is from 0.5 to 5 weight percent based on the weight of said chromium compound and said support. The chromium catalyst composition of claim 1 wherein said chromium catalyst composition consists essentially of: (a) a support that is selected from silica and silica/titania, and (b) a hexavalent chromium compound, wherein said hexavalent chromium compound is activated at a temperature from 800 °C to 925 °C. The chromium catalyst composition of claim 1, wherein said hexavalent chromium compound is activated at a temperature from 600 °C to 700 °C. The chromium catalyst composition according to claim 1 wherein said support consists of silica. The chromium catalyst composition according to claim 1 wherein said support consists essentially of silica and a refractory metal oxide selected from alumina, boria, magnesia, thoria, zirconia, titania, and mixtures of two or more of said refractory metal oxides. The chromium catalyst composition according to claim 5 wherein said support consists of silica and titania. The chromium catalyst composition according to claim 1 wherein said support has a surface area from 100 to 300 square meters per gram. The chromium catalyst composition according to claim 1 wherein said support has a pore volume from 0.5 to 2.5 cubic centimeters per gram. The chromium catalyst composition according to claim 1 wherein said support has a pore volume from 1 to 2 cubic centimeters per gram. The chromium catalyst composition according to claim 1 wherein the amount of said hexavalent chromium is from 1 to 4 weight percent based on the weight of said chromium compound and said support. The chromium catalyst composition according to claim 1 wherein the amount of said hexavalent chromium is from 1 to 3 weight percent based on the weight of said chromium compound and said support. The chromium catalyst composition according to claim 1 wherein said hexavalent chromium has been activated at a temperature from 750 °C to 1000 °C. The chromium catalyst composition according to claim 1 wherein said hexavalent chromium has been activated at a temperature from 800 °C to 1000 °C. A process to homopolymerizing ethylene, or copolymerizing ethylene with a comonomer, to produce an ethylene polymer that has an increased amount of long chain branching and a decreased amount of die swell, said process comprising polymerizing ethylene with a chromium catalyst composition that comprises: (a) a support that comprises silica, wherein said support has a surface area (SA) to pore volume relationship as follows 0.5 ≤ Pore volume < f(SA) wherein said f(SA) is (1.14x10 -7 )(SA) 3 - (1.19x10 -4 )(SA) 2 + (3.19x10 -2 )(SA) + 0.20; wherein the pore volume is given in (cm 3 /g) and the surface area is given in (m 2 /g); and (b) a hexavalent chromium compound; wherein the surface concentration of said hexavalent chromium on said support is from 0.4 to 1 hexavalent chromium atoms per square nanometer, said support has a surface area from 50 to 500 m 2 /g, and the amount of said hexavalent chromium is from 0.5 to 5 weight percent based on the weight of said chromium compound and said support. The process of claim 14, wherein a chromium catalyst composition is used as defined in any of claims 2 to 13. The process of claim 14, wherein said support is calcined at a temperature from 750 °C to 1000 °C; and wherein said hexavalent chromium compound is activated at a temperature from 600 °C to 700 °C; and wherein said polymerizing is conducted in the presence of a cocatalyst selected from triethylaluminum, triethylboron, and mixtures of said cocatalysts. The process according to claim 14 wherein said polymerizing is conducted in the presence of a cocatalyst selected from trialkylaluminum compounds, trialkylboron compounds, and mixtures of said cocatalysts. The process according to claim 14 wherein said polymerizing is conducted in the presence of a trialkylaluminum cocatalyst. The process according to claim 18 wherein said trialkylaluminum cocatalyst is triethylaluminum. The process according to claim 14 wherein said polymerizing is conducted in the presence of a trialkylboron cocatalyst. The process according to claim 20 wherein said trialkylboron cocatalyst is triethylboron.

Inventors: BADLEY RICKEY D, MCDANIEL MAX P, ROLLMANN KENT W, BADLEY, RICKEY D., MCDANIEL, MAX P., ROLLMANN, KENT W.
Applicants: PHILLIPS PETROLEUM CO, PHILLIPS PETROLEUM COMPANY
Application year: 1994
Main classification: C08F4
IPC codes: C08F4, C08F10